Hindawi

International Journal of Chemical Engineering

Volume 2022, Article ID 1699196, 6 pages
https://doi.org/10.1155/2022/1699196

Research Article
Optimization of Parameters Using Taguchi Orthogonal Array
Design for an Intensified Per-Pass Conversion of Alphabutol
Technology in Butene-1 Production
®
Hamoud Alenezi ,1 Zainab Haidar,2 and Mirdul Das2
1
Process Systems Engineering Centre (PROSPECT), Research Institute for Sustainable Environment,
School of Chemical and Energy Engineering, Universiti Teknologi Malaysia, UTM Johor BahruS, Skudai, Johor 81310, Malaysia
2
EQUATE Petrochemical Company, Ahmadi 61001, Kuwait

Correspondence should be addressed to Hamoud Alenezi; homoudkt@gmail.com

Received 29 September 2021; Accepted 15 March 2022; Published 13 April 2022

Academic Editor: Andreas Bück

Copyright © 2022 Hamoud Alenezi et al. This is an open access article distributed under the Creative Commons Attribution
License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is
properly cited.
Taguchi orthogonal design was used in this study to investigate the effects of three operational parameters (i.e., reactor tem-
perature, reactor pressure, and catalyst ratio on per-pass conversion (PPC)). The optimal PPC was calculated from the predicted
response function at 48°C of reactor temperature, 21 kg/cm2g of reactor pressure, and catalyst mole ratio of 2.50. Under these
conditions, the PPC was estimated to be 87.1 per cent, with a maximum SNR of 38.95. In line with the delta ranking, the decreasing
order of significance of each process parameter on the average per-pass conversion (PPC) was x1 > x2 > x3, with percentage
contributions of 50.6%, 26.1%, and 23.3% for reactor temperature, temperature, and catalyst mole ratio, respectively. The optimal
production condition can therefore be attained at a larger scale with the higher per-pass conversion of butene-1.

1. Introduction conclusion of the study period (LLDPE). In 2020, the US

The increasing demand for plastic packaging for different
food products, medicines, and other sectors have led to a rise
in demand for butene-1 markets [1]. This is because butene-
1 is the most commonly used in the polyethene and plastic
packaging industry, as it is commonly used as a comonomer
in a variety of polyethene applications, including elastic and
solid packaging materials [2]. Asia-Pacific is the largest
market for butene-1, and the growing demand in the pol-
yethene industry is due to the region’s rapid development
[3]. The demand for butene-1 is driven by the growing
plastic sector in Asia-Pacific emerging markets. The butene-
1 overall productivity is estimated to exceed the US $3.6
trillion in 2020, with the additional US $5.3 trillion estimated
by 2027, representing a 5.9% compound annual growth rate
(CAGR) for the 2020–2027 analytic era [4]. Linear low-
density polyethylene (LLDPE), for example, is expected to
grow at 6.4 per cent CAGR and reach $3.6 trillion by the
market for butene-1 is anticipated to be worth $964.6
million. China, the world’s second-biggest economy, is
predicted to surpass US $1.1 trillion by 2027, resulting in a
compound annual growth rate (CAGR) of 9.1 per cent
throughout the research period of 2020 to 2027 [4]. Japan
and Canada are two more noteworthy markets, with ex-
pected growth rates of 3.2 per cent and 5.4 per cent, re-
spectively, from 2020 to 2027 [4]. Germany, on the other
hand, is predicted to develop at a compound annual growth
rate of around 3.7 per cent in Europe (CAGR) [4]. The
activity chain in the butene-1 system adds value to the ul-
timate product.
Butene-1 is a monobutene that can come from a variety
of sources. The most common sources for butene-1 pro-
duction are natural gas, naphtha, butane, and ethylene.
Multiple technologies are used to generate sources such as
refineries, steam cracking of C4 hydrocarbons, ethylene
dimerization, and butane dehydrogenation [5]. The
2 International Journal of Chemical Engineering
®
technology of Alphabutol is used to produce polymer grade
butene-1 from high purity ethylene as the raw feedstock.
Butene-1 is a comonomer utilized in the manufacture of
®
various grades of polyethene. The Alphabutol technology,
which works in the liquid phase and employs a dissolved
catalyst, selectively dimerizes ethylene to form butene-1. The
manufacture of butene-1 polymer grade using Alphabutol
technology was created in the late 1980s by a single licensor
® sections involved in this process which include the reaction,
in the globe, namely, Institut Français du Petrole (IFP) in
collaboration with SABIC. It is a dimerization of ethylene to
®
butene-1 [6]. Alphabutol is preferred over other com-
pounds because butene-1 is readily accessible in the C4
fraction of naphtha crackers, but its recovery at a high purity
level requires a complex strategy [7]. Among the numerous
possible schemes, the most frequently used is to first extract
or selectively hydrogenate butadiene, usually accompanied
by the complete removal of isobutene via high-conversion
MTBE synthesis, preceded by the separation of butene-1
from the other C4s via super fractionation or molecular
sieves [8]. This method of processing has the significant
disadvantage of being more costly in terms of investment
®
and operational costs than the Alphabutol approach [9].
This system requires a local outlet for butadiene and MTBE
to be economically feasible. While this advantageous sce-
nario may exist for more industrialized nations, namely, the
United States of America, Japan, and Europe; it is not always
the case in other countries. Coproduction of MTBE may be
challenging for a petrochemical firm owing to recent MTBE
bans in many places [10]. A challenging market for these
related products, or a shortage of C4 cuts in the case of
ethane crackers, has prompted LLDPE producers to consider
®
ethylene dimerization by Alphabutol for the synthesis of
butene-1 [11].
®
The existing Alphabutol operations have inherent
challenges in terms of operating units at a high rate of
production which calls for the minimization of unit pro-
duction costs. Making trade-offs between these two choices
has been a source of contention for a wide variety of
businesses. It is critical to understand that many industries
have difficulties with pump-around loop (PAL) operation
owing to an inconceivable decrease in the total heat transfer
coefficient (U) usually caused by pipe fouling [12]. This
increases the unit maintenance cost as well production
limitation occasioned by potential personal risks to the
technicians while using the high-pressure water jet. The
dangers associated with performing the industrial-scale
experimental test are relatively high and this is large to the
long residence period which usually leads to the difficulty in
regulating the resulting chain reactions is critical to inves-
tigate the effects of reaction parameters on pilot plant size to
mitigate this impact. The influence of operational parame-
ters such as catalyst ratio, pressure, and temperature on the
per-pass conversion (PPC) was thoroughly explored in this
work utilising the orthogonal design matrix.
2. Material and Methods
®
2.1. Description of the Pilot Plant. The Alphabutol pilot
plant utilizes proprietary homogeneous titanium-based
catalyst which demonstrates high dimerization activity
coupled with excellent selectivity to butene-1 at moderate
pressures and temperatures. This performance is influenced
by the catalyst composition and reaction parameters. The
catalytic ethylene dimerization to butene-1 also generates
ethylene polymer as a side reaction. There are three main
catalyst removal, and distillation. In the reaction section, the
reactor is operating in the liquid phase at bubble point
conditions. Fresh and recycled ethylene is fed to the liquid
phase containing butene and hexene via a gas distributor, to
make sure all ethylene is dissolved.
The homogeneous catalyst is continuously fed to the
reactor section. The dimerization reaction is carried out at
about 50–60°C and 20–30 atm with a reaction residence time
of about 4 to 6 hours. The homogeneous catalytic reaction
proceeds at an ethylene per-pass conversion of about
80–85% with a selectivity to butene-1 approaching 92%. The
exothermic heat of the reaction is removed utilising an
external pump-around loop (PAL). In the catalyst removal
section, the active catalyst is deactivated using an amine
compound and the spent catalyst is then incinerated at a
higher temperature. In the distillation section, there are two
columns; the first one is to recover unreacted ethylene from
the top. The second column is to separate the desired
product of butene-1 as overhead and the bottom is hexenes
as heavies.
Data were collected at different operating conditions in
the plant with mass and heat balance in mind. The data
consisted of reactor parameters which consider pressure,
temperature, catalyst ratio, and overall heat transfer coef-
ficient. These parameters were collected from distributive
control system (DCS) using a calibrated transmitter. The
data were collected as shown in Figure 1, showing the
®
Alphabutol process flow diagram with parameter locations.
All the data were collected from DCS using calibrated in-
struments before the experiment started for 300 days. These
data were uploaded to Excel and analysed, excluding data
that had errors in terms of power failure or runaway reaction
during the experiment. Table 1 illustrated the 23 elements of
the pilot plants.
2.2. Calibration of Equipment and Analyser
2.2.1. Equipment Calibration. Before the experiment, a
qualified technician calibrated the instruments used. For the
equipment calibration, a visual inspection of the instru-
ments, tubing, wiring, instrument air, blowback, and con-
nections were all performed for each installation. The “Hart
Communicator” was then connected to the transmitter,
and the diagnostic messages were recorded in the history
form for further analysis. The transmitter was taken out of
service to prevent the interference of the service fluid. The
test equipment was then connected to the input and
output of the transmitter. For cold junction compensa-
tion, the terminal temperature of the transmitter at stable
ambient conditions was taken via the Hart Communi-
cator. The terminal temperature value obtained was input
International Journal of Chemical Engineering 3

F10
F3
Condenser
Flare
flare
Dimer
Reactor
Condenser A1
F5 F1
P1 A2 Condenser
T2
PA Loop T4
F2 Recycle
F9 Column Recycle Butene-1
Column Bulene-1
Column
Reflux Column
A4
Drum Reflus Drum
F4
T5 A5 A3
A6

T3 Reboller

Reboiler
F6 F7

Butene-1

C6+

C6+Cooler F8

®
Figure 1: Alphabutol schematic process flow diagram.

Table 1: The transmitters as well as the range and calibration frequency.

Abbreviation Instrument Type
Reactor temperature T1 Transmitter
Reactor pressure P1 Transmitter
PA loop process outlet temperature T2 Transmitter
PA loop process inlet temperature T3 Transmitter
PA loop CWS temperature T4 Transmitter
PA loop CWR temperature T5 Transmitter
Calculated flow at DCS
PA loop flow F1
from pump amperage
Ethylene feed flow F2 DP transmitter
Recycle ethylene flow F3 DP transmitter
Catalyst flow F4 Coriolis
Cocatalyst flow F5 Coriolis
Amine flow F6 Coriolis
1-butene production flow F7 DP transmitter
C6 + production flow F8 DP transmitter
PA loop cooling water flow F9 DP transmitter
Purge flow F10 DP transmitter
Spent catalysts flow level L1 DP transmitter
Ethane recycle A1 Analyzer
Butene recycle A2 Analyzer
2_BUTENE in 1-butene product A3 Analyzer
3METH-1PENT in 1-butene product A4 Analyzer
3METH-1PENT in 1-butene product A5 Analyzer
1-butene purity in 1-butene product A6 Calculated value at DCS

as the manual compensation value in the test instrument
before the simulation of the thermocouple. The terminal
temperature of the transmitter was stabilized throughout
the calibration process. Low, mid, and high input of the
calibration range to the transmitter was applied and the
test equipment readings were recorded. If the AS FOUND
values exceed the set tolerance, the “Found out of
tolerance” box is ticked. However, if the AS FOUND
values exceed 1/2 of the tolerance, the LEFT readings are
recalibrated and recorded. The calibration, final readout
device, and functional loop check are verified to be sure
the last alarm is checked and are within the estimated
accuracy. Finally, the transmitter is placed back in service
after the calibration is completed.
4 International Journal of Chemical Engineering
2.2.2. Calibration of Gas Chromatograph Analyser. Firstly,
the sample filter was inspected and the integrity of the
sample system such as heat trace, sample pressure, sample
flow, and sample cooler was checked. The oven temperature
was checked and “import” is checked to transfer the current
running “method” and last data and save it as the process
before calibration with correct extensions. The carrier gas
was also checked for proper pressure and flow settings. The
process sample was closed while keeping the “run” button
switched on with only the carrier gas allowed to flush out the
columns completely for 3 cycles, while at the same time
checking for a good baseline. The GC was then operated on
the process sample using the proper pressure and flow
settings, while the sample heater was monitored closely. The
calibration sample container was then closed and the sample
take-off and the conditioning panel was visually monitored
to prevent equipment leakage.
®
2.3. Description of Theoretical Approach to Alphabutol Pilot
Plant Process. The focus of the ethylene dimerization pro-
cess is to produce high selectivity of butene-1 by improving
the catalyst system. In previous research, only a few im-
provements were found to improve the selection of butene-1
®
based on Alphabutol technology. However, past im-
provement was focused on improving the advance control of
the unit as reported by Jean-Marc [13], not to focus on
optimizing reactor condition or addressing fouling issues.
However, the researchers focused on the general hydro-
carbon plant, which is a wide field that cannot be referenced
®
for the Alphabutol technology. Therefore, there is still
room for improvement particularly research that focuses on
®
fouling problems in industrial Alphabutol technologies. It
is not possible with an existing catalyst to prevent fouling;
however, it is possible with optimizing reaction parameters
to reduce fouling and increase butene-1 selectivity. The
resulting findings could provide useful insights and guide-
lines to optimize and smoothen the process in a commercial-
scale plant as more companies build new plants.
2.4. Design of L9 (33) Taguchi Orthogonal Array. The set of
data comprised reactor parameters such as pressure, tem-
perature, catalyst mole ratio, and heat transfer coefficient
overall. These parameters were obtained via a calibrated
transmitter through the use of the distributive control
system (DCS). The main objective is to study how those
input characteristics affect the output response which passes
per conversion (PPC). Taguchi experimental design matrix
with a standard orthogonal array L9 (33) was used to examine
the effects of three parameters on the per-pass conversion
(PPC). The lower, middle, and upper levels of optimized
factors were selected based on the preliminary data gathered
for 300 days under a range of operating conditions
throughout the plant, with a special focus on mass and heat
balance. The limits of each variable were selected since
higher, middle, or lower settings resulted in a runaway or
sluggish reaction, respectively. The factor ranges are pre-
sented in Table 2.
The per-pass conversion (PPC%) was estimated from the
mass balance of the plant:
100 − A1 − A3 /100􏼁 ∗ F10 + F3 􏼁􏼁
PPC � 1 − 􏼠 􏼡 ∗ 100,
100 − A1 − A3 /100􏼁 ∗ F10 + F3 􏼁 + F2 􏼁􏼁
(1)
where A1 is ethane recycled in PPM, A3 is butene-2 in
butene-1 product in PPM, F2 is ethylene feed flow in kg/hr,
F3 is the recycle ethylene flow in kg/hr, and F10 is the purge
flow in kg/hr. The results of the per-pass conversion trials
®
were determined using the MINITAB statistical software
package (version 18.1, United States). As shown in (2), the
signal-to-noise ratio, which is the logarithmic function of the
intended output (PPC), serves as the goal function for the
maximization of the butene-1 production. The larger-is-
better is used for the maximization.
(1/PPC)2
Maximized(Large−the−better) � −10 ∗ log 10􏼨􏽘 􏼩,
n
(2)
where “PPC” is the signal and “n” is the number of trials
consisting of nine runs. Using the butene-1 manufacturing, a
total of 27 experimental units were conducted using the L9
(33) orthogonal design matrix in a 3 × 9 parametric study,
totalling nine unique tests. The Taguchi technique was used
to conduct an analysis of variance (ANOVA) on the response
(PPC) of butene-1 production. The ratio (F) and p value
(p < 0.005) were computed using the variables in the experi-
mental design that were adjudged to be 5% confidence level.
3. Results and Discussion
3.1. Determination of Optimum Conditions by Taguchi
Method. The Taguchi orthogonal design was used to opti-
mize the per-pass conversion (PPC%). The optimal butene-1
production condition was established, and the statistical
relevance of the process parameters on the PPC was examined
appropriately. Table 3 shows the per-pass conversion (PPC%)
of the butene-1 produced as well as the acquired signal-to-
noise ratio (SNR) and total mean signal-to-noise (SNRT)
values. The summary of the generated experimental trials is as
shown in Table 3. Based on the largest donating rule, the trial
with the largest SNR ratio was estimated to be the predicted
optimum condition for the production of butene-1 using the
®
Alphabutol technology [14]. The optimum process condi-
tion was attained at 48°C of reactor temperature, 21 kg/cm2g
of reactor pressure, and 2.50 of catalyst mole ratio. Under this
condition, PPC was estimated to be 87.1% as obtainable in
trial 4 with the highest SNR of 38.95. The results were ob-
tained for the optimum condition at which the production
parameters jointly optimized the PPC%. Hence, by using the
above conditions, improved production of butene-1 was
achievable at an optimized per-pass conversion.
3.2. Statistical Analysis of Means (ANOM). The mean analysis
was used to determine the most effective process param-
eters for optimal per-pass conversion (PPC). The average
International Journal of Chemical Engineering 5

Table 2: Factor to optimize the PPC.

Variable Symbol Low setting (−1) Mid setting (0) High setting (+1)
Reactor temperature (°C) X1 48 51 54
Reactor pressure (kg/cm2g) X2 18 19.2 21
T2/LC mole ratio X3 1.8 2.0 2.5

Table 3: Coded Taguchi L9 (3^3) orthogonal design.

Reactor temperature Reactor pressure Catalyst mole Per-pass Signal-to-noise
Experiment number (°C) (kg/cm2g) ratio conversion ratio
X1 X X3 (PPC) % (SNR)
1 1 1 1 85.6 38.8426
2 1 2 2 86.5 38.7179
3 2 1 2 90.3 38.8573
4 1 3 3 87.1 38.9525
5 2 2 3 86.9 38.7610
6 2 3 1 83.2 38.5609
7 3 1 3 89.4 38.7470
8 3 2 1 88.2 38.8499
9 3 3 2 85.6 38.8426

Table 4: Response matrix for per-pass conversion mean (larger is better).

Level Reactor temperature ( C) Reactor pressure (kg/cm2g) Catalyst mole ratio
1 88.03 86.93 86.69
2 86.04 87.74 87.60
3 87.33 86.72 87.11
Delta 1.98 1.02 0.91
Rank 1st 2nd 3rd

Main Effects Plot for Means

Data Means
Reactor Temperature (oC) Reactor Pressure (kg/cm2g) Catalyst mole ratio
88.0

87.5
Mean of Means

87.0

86.5

86.0
1 2 3 1 2 3 1 2 3
Figure 2: Relative mean of PPC% for each factor at three different levels.

response means, extremum, and delta difference
(max–min) were calculated, where max and min de-
note the maximum and minimum average response
means, respectively. The mean effects of each process
factor were calculated using the value generated by
the difference between their extremums [15]. Table 4
summarizes the average values for per-pass conversion
optimum means.
Figure 2 shows the individualistic effects of each process
variable on the per-pass conversion. The maximum average
passes per conversion were obtained as 88.03% at level-1 of
reactor temperature (48°C), 87.74% at level-2 of reactor
6 International Journal of Chemical Engineering
pressure (19.2 kg/cm2g), and 87.33% at level-1 of catalyst
mole ratio (1.8). The decreasing order of significance of each
process parameter on the average per-pass conversion (PPC)
was x1a0 > x2 > x3 following the delta ranking with a corre-
sponding percentage of 50.6%, 26.1%, and 23.3% for the
reactor temperature, temperature, and catalyst mole ration,
respectively.
The results obtained indicated that the reactor tem-
perature has the most significant contribution to per-pass
conversion (PPC%) with approximately half the pro-
portion, whereas the catalyst mole ratio has the least. The
temperature and pressure in the reactor may be regulated
to modulate the per-pass conversion. The reactor is
conducted at the bubble point, with a composition very
similar to that of a binary combination of ethylene and
butene-1 [16]. The pressure within the reactor is equal to
the sum of each component’s partial pressures. Because
once the temperature is set, each component’s vapour
pressure is enforced. The temperature of the reactor may
be regulated by altering the flow of cooling water to the
pump that surrounds the heat exchanger. Controlling the
pressure is accomplished by controlling the ethylene feed
valve. The residence duration in the reactor is determined by
the amount of product removed under level control. The
catalyst flow rate is the sole remaining variable and once the
pressure and temperature are set, the only method to alter
the feed input is to alter the catalyst mole ratio [16].
4. Conclusion
The manufacture of polymerization grade butene-1 via
®
Alphabutol technology involves the utilization of high-
purity ethylene as raw feedstock. Butene-1 is utilized in
the manufacture of various polyethene grades as a co-
®
monomer. In the liquid phase of Alphabutol technology,
which works with a dissolved catalyst, ethylene is selec-
tively dimerized into butene-1. This study examined the
effects of the PPC on the reactor temperature, reactor
pressure, and catalyst ratio using the Taguchi orthogonal
design method. The optimal PPC was derived using the
predicted response function at 48°C of reactor tempera-
ture, 21 kg/m2g of reactor pressure, and a catalyst mole
ratio of 2.50. PPC was thus estimated to be 87.1 per cent
with the highest SNR of 38.95. The result was obtained for
the optimum condition, which concurrently maximised
the production parameters by the PPC per cent. Thus,
using the above circumstances, increased synthesis of
butene-1 at an optimum PPC was feasible.
Data Availability
The data used to support the findings of this study are in-
cluded in the article.
Conflicts of Interest
The authors declared that there are no conflicts of interest
whatsoever.
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